Kohler 4645-RA-96 Operating instructions

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IMPORTANT INFORMATION

SAVE THESE INSTRUCTIONS

WARNING: Risk of injury or water damage. Contents of vessel

under pressure can cause severe injury. Do not open or service

before reading service instructions. Turn off water supply and

ﬂush the unit to release pressure before attempting any service.

CAUTION: Risk of product damage. Do not use any oils or

lubricants on the Pressure Lite

TM system.

CAUTION: Risk of product damage. The ﬁttings in this toilet

require no adjustment (except for possible gap clearance

adjustment and winterizing). The ﬁttings in this toilet are preset.

Any adjustment or modiﬁcations of the product are not normal

usage and void the warranty.

WARNING: Risk of injury or product damage. Handle vitreous

china products very carefully. Vitreous china can break and chip

if you overtighten bolts and nuts.

NOTICE: For service and warranty on the Sloan Flushmate vessel

and related components, see the Sloan Flushmate Owner’s Service

Manual.

Follow all local plumbing codes.

Thank You For Choosing Kohler Company

Thank you for choosing the Bold Look of Kohler. Kohler craftsmanship

offers you a rare combination of proven performance and graceful

sophistication that will satisfy you for years to come. The

dependability and beauty of your Kohler toilet will surpass your

highest expectations. We’re very proud of our products here at Kohler

and we know you will be too.

Please take a few minutes to study this Homeowners Guide. Pay

special attention to the Care and Cleaning instructions.

All information in this manual is based upon the latest product

information available at the time of publication. At Kohler, we

constantly strive to improve the quality of our products. We reserve

the right to make changes in product characteristics, packaging or

availability at any time without notice.

1044956-5-B 2 Kohler Co.

Your Kohler Toilet

Your Kohler toilet combines outstanding function, comfort, and

performance with remarkable style and class.

This Kohler toilet was designed to use only 1.4 gallons (5.3 L) of water

for each ﬂush. This ensures that your toilet will provide exceptional

performance that is comparable to our previous 3.5 gallon (13.2 L)

models. Your toilet exceeds ASME performance standards for

low-consumption toilets. It was designed with a large, glazed trapway

to keep waste moving without blockage.

Crafted from a clay mixture that is ﬁred at an intense heat to vitrify

the clay and fuse the glaze, your Kohler toilet is scratch- and

abrasion-resistant. Its surface won’t stain, discolor, rust, or fade. Every

component in your Kohler toilet is speciﬁcally designed to increase the

toilet’s useful life.

How to Use This Manual

This manual is designed to help you troubleshoot and repair any

problems that may develop with the operation of the toilet. If a

problem occurs:

Refer to the Troubleshooting section to determine a probable

cause.

Follow the maintenance and repair instructions in this manual to

correct the problem.

Check the Service Parts section to determine the part numbers for

any replacement parts necessary.

Use the information on the back cover of this manual to contact

Kohler Company to order parts, or for help if you cannot correct

the problem.

Care and Cleaning

NOTE: See the special instructions before you clean Artist Edition

products.

Clean the outside surface of your vitreous china toilet with mild soap

and warm water. Wipe the entire surface completely dry with a clean,

soft cloth. You may use soft abrasive cleaners when necessary to clean

your toilet. Do not use strong abrasive cleaners, as they will scratch

and dull the surface. Wipe any splashes of cleaner solutions from

plastic or plated surfaces immediately. Use toilet bowl cleaners on the

inside of the bowl only.

Kohler Co. 3 1044956-5-B

Care and Cleaning (cont.)

If the surface becomes excessively dirty, use a general purpose cleaner

such as: Fantastik

®

All Purpose, Lysol

®

Basin, Tub and Tile Cleaner,

Soft Scrub

®

Multi Purpose, Scrub Free

®

Disinfectant Bathroom Cleaner,

Clorox Clean-Up

®

, Spic and Span Liquid, Comet

®

Liquid Bathroom

Cleaner, Scrubbing Bubbles

®

Bathroom Cleaner, Bar Keeper’s Friend

®

,

or Bon Ami

®

.

Over time, hard water deposits may clog toilet rim holes and

trapways. To clean, use a commercial cleaner that is recommended for

removing hard water deposits. Follow the cleaner manufacturer’s

instructions.

WARNING: Risk of property or product damage. Do not use

in-tank cleaners in your toilet. Products containing chlorine

(calcium hypochlorite) can seriously damage ﬁttings in the tank.

This damage can cause leakage and property damage.

Kohler Company shall not be responsible or liable for any tank ﬁtting

damage caused by the use of cleaners containing chlorine (calcium

hypochlorite).

For Artist Edition toilets: Do not use bristle brushes or abrasive

sponges to clean the surface of your Artist Edition toilet. They will

scratch the decorated surface. Gold and Platinum used on decorative

products are like ﬁne jewelry. Use only warm water to clean, and dry

with a soft cloth. Do not let cleaners sit or soak on Artist Edition

surfaces. Rinse and wipe the toilet surface to prevent soap buildup. If

the surface of your Artist Edition toilet becomes excessively dirty, use

Glass Plus

®

or a liquid dish soap with water.

Toilet Seats: Avoid using abrasive cleaners, detergents, disinfectants or

cleaning products in aerosol cans.

Do not allow abrasive chemicals or cosmetics (such as ﬁngernail polish

or aftershave) to come in contact with the toilet seat, as they can

damage the ﬁnish.

Use a soft sponge or cloth to clean the toilet seat. Rinse the seat clean

and dry with a soft towel. Let the seat air dry and ensure that the

hinge area dries completely.

Clean the seat with dishwashing liquid and water or with any of the

following products: Gel Gloss

®

, Scrub Free

®

Mildew Stain Remover,

Formula 409

®

All Purpose Cleaner, Mr. Clean

®

Lemon Fresh, Cinch

®

,

Glass Plus

®

, or Fantastik

®

All Purpose.

Painted wood seats require special care and cleaning. Use only mild a

detergent such as dishwashing soap.

1044956-5-B 4 Kohler Co.

Operation

The vitreous china bowl and tank direct the ﬂushing water ﬂow, and

house the Pressure Lite system.

The vessel contains the complete operating cartridge assembly, and is

the container for the pressurized 1.4 gallons (5.3 L) of water used for

each ﬂush.

The control components consist of the pressure regulator and the air

inducer. These components work with the incoming, pressurized,

supply-line water to provide a regulated pressure ﬂush to the toilet

bowl.

A complete ﬂush cycle is two separate functions.

When the trip lever is operated, the vessel plunger assembly is

pressed, allowing pressurized water to be directed to the bowl for

complete ﬂushing action. As the water level in the vessel drops the

plunger will close, stopping water ﬂow to the bowl.

A checkpoint built into the vessel assembly allows any discharge of

water into the vitreous china tank to drain directly into the bowl.

After ﬂushing, a charge cycle takes place. Supply line water ﬂows into

Air Inducer

Actuator

Vessel

Screen

Water

Air

Pressure Regulator

Trip Lever

Supply Hose

Overflow Valve

Kohler Co. 5 1044956-5-B

Operation (cont.)

the vessel through the screen and pressure regulator. The water then

ﬂows across the air inducer, which mixes a small amount of air with

the water, ﬁlling the vessel until a pressure of approximately 35 psi (2.5

Kg/cm squared) is reached. The toilet will be ready for the next ﬂush

within 60 to 90 seconds. If the toilet is not ready for the next ﬂush

within that time, please refer to the Troubleshooting section.

1044956-5-B 6 Kohler Co.

Gap Clearance

If the toilet does not activate, the gap between the actuator and

the plunger arm may need to be reset. Make sure the trip lever

handle is installed, and the trip lever nut is tight. This is a

left-hand thread; turn counterclockwise to tighten.

Make sure the water supply is on, and the supply line water has

stopped ﬂowing into the toilet.

Loosen the setscrew. Turn the actuator until there is a 1/16″ (2

mm) - 1/8″ (3 mm) gap between the actuator and the plunger

arm. Turn the actuator clockwise to increase the gap.

Tighten the setscrew after the gap is properly adjusted.

NOTE: Loss of gap clearance adjustment could cause leakage into

the toilet bowl due to the plunger not sealing properly. This

condition could cause a continual ﬂow of water. If the problem is

not corrected after adjustment, refer to the Troubleshooting section.

Setscrew

Plunger Arm

Actuator

1/16" (2 mm) –

1/8" (3 mm) Gap

Kohler Co. 7 1044956-5-B

Winterizing Your Toilet

Turn off the water.

Drain the tank by ﬂushing. Press the actuator down for

approximately one minute to drain the water from the vessel

assembly.

Disconnect the water supply line to the toilet.

Remove the supply shank, and drain the water from the tank.

Press the actuator one more time, then pull the actuator up to

allow air into the vessel.

Add antifreeze to the toilet bowl water to prevent freezing. Use

recreational-type antifreeze commonly used in campers, motor

homes, and boats.

To restart the toilet, ﬁrst reconnect the water supply line to the

toilet. Then turn on the water supply, and let the system

pressurize for at least one minute.

Check for leaks, and retighten any leaking connections.

Air Inducer

Actuator

Vessel

Screen

Trip Lever

Supply Hose

Overflow Valve

Pressure

Regulator

1044956-5-B 8 Kohler Co.

Winterizing Your Toilet (cont.)

NOTE: Refer to the Sloan Flushmate

®

Owner’s Service Manual for

more information.

One-Year Limited Warranty

For the U.S.A. and Canada Only

KOHLER

®

plumbing ﬁxtures, faucets and ﬁttings are warranted to be

free of defects in material and workmanship for one year from date of

installation.

Kohler Co. will, at its election, repair, replace or make appropriate

adjustment where Kohler Co. inspection discloses any such defects

occurring in normal usage within one year after installation. Kohler

Co. is not responsible for removal or installation costs.

To obtain warranty service, contact Kohler Co. either through your

Dealer, Plumbing Contractor, Home Center or E-tailer, or by writing

Kohler Co., Attn.: Customer Service Department, 444 Highland Drive,

Kohler, WI 53044, USA, or by calling 1-800-4-KOHLER from within the

USA, 1-800-964-5590 from within Canada and 001-877-680-1310 from

within Mexico.

Implied warranties including that of merchantability and ﬁtness for

a particular purpose are expressly limited in duration to the duration

of this warranty, Kohler Co. disclaims any liability for special,

incidental or consequential damages. Some states/provinces do not

allow limitations on how long an implied warranty lasts, or the

exclusion or limitation of special, incidental or consequential damages

so these limitations and exclusions may not apply to you. This

warranty gives you speciﬁc legal rights. You may also have other

rights which vary from state/province to state/province.

This is our exclusive written warranty.

Notes:

1. There may be variation in color ﬁdelity between catalog images and

actual plumbing ﬁxtures.

2. Kohler Co. reserves the right to make changes in product

characteristics, packaging or availability at any time with out notice.

Kohler Co. 9 1044956-5-B

One-Year Warranty

For Mexico Only

KOHLER CO.

It is recommended that at the time of purchase, you verify that all

accessories and components are complete in this package.

This Kohler product is warranted to be free of defects in material and

workmanship for one (1) year from the date of purchase as shown on

the invoice or receipt.

1. Kohler Co. will only service its commercialized products through its

authorized distributors.

2. To obtain warranty service, please present the invoice and

corresponding warranty.

3. Through its authorized distributors, Kohler Co. promises to repair

the defective product or provide a new replacement or an equivalent

model (in those cases that the model has been discontinued) when the

product is beyond repair, without any charge to the consumer.

4. The time of repair will not exceed six (6) weeks commencing on the

date the product is received.

5. It is recommended that the consumer save the invoice or receipt as

additional protection, as it may substitute the warranty in the case that

there is a discrepancy in the validity of the warranty.

EXCEPTIONS AND RESTRICTIONS

The Warranty will not be valid in the following cases:

1. When the product is not operated in accordance with the

instructions concerning use and operation set forth in the owner’s

manual or installation instructions, and when the recommendations

and warnings included are not observed.

2. When the product has been modiﬁed or dismantled partially or

totally; or has been used in a negligent fashion and as a consequence

has suffered damages attributable to the consumer, individual, or

hardware not authorized by Kohler Co.

3. This warranty does not cover the damages as a result of disaster

such as ﬁre or acts of God, including ﬂooding, earthquake, or electric

storms, etc. To obtain a list of distributors in your area where you can

exercise your rights under this warranty, please call 001-877-680-1310.

KOHLER CO., KOHLER, WI 53044 U.S.A.

IMPORTER:

INTERNACIONAL DE CERÁMICA, S.A. DE C.V.

1044956-5-B 10 Kohler Co.

One-Year Warranty (cont.)

AV. CARLOS PACHECO NO. 7200

CHIHUAHUA, CHIH., MEXICO C.P. 31060

TEL: 52 (14) 29-11-11

Troubleshooting Guide

Troubleshooting Tips

NOTE: This troubleshooting guide is for general aid only. For

warranty service, contact your dealer or wholesale distributor.

Troubleshooting Table

Symptoms Recommended Action

1. Poor ﬂush. A. Clean under the bowl rim.

B. Plunge the bowl, auger the trap, and auger

the drain to clear any blockage.

C. Adjust the gap between the actuator and

plunger arm to approximately 1/8″ (3

mm).

D. Fully open the supply stop.

E. Clean the screen with a medium to hard

bristle brush. Replace the screen if

necessary. (Phone 1-800-533-3450 for

assistance.)

F. Clean or replace the ﬂow regulator.

G. Refer to installer/dealer for assistance.

2. No ﬂush. A. Fully open the water supply stop.

B. Tighten the nut (turn counterclockwise to

tighten).

C. Hook the plunger arm over the trip arm.

D. Clean the screen. (Phone 1-800-533-3450

for assistance.) Replace the screen if

necessary

E. Clean or replace the ﬂow regulator.

F. Replace inlet components. (Phone

1-800-533-3450 for assistance.)

3. Bowl water

continues to ﬂow

or tank ﬁll water

will not shut off.

A. Adjust the gap between the actuator and

plunger arm to approximately 1/8″ (3

mm).

Kohler Co. 11 1044956-5-B

Troubleshooting Guide (cont.)

Symptoms Recommended Action

B. Repair or replace the plunger arm (refer to

installer/dealer for assistance).

C. Replace the lower supply group.

For additional assistance, also refer to the Sloan Flushmate

®

Owner’s

Service Manual supplied with the tank.

1044956-5-B 12 Kohler Co.

Service Parts

**Finish/color code required.

51624

Screw

1044434

1044435

(LH)

(RH)

Plunger Arm Assembly

78132

Trip Lever Nut

1045277**

1045276**

(RH)

(LH)

Trip Lever

51533

Nut

42397

84464

Locknut

42398

Washer

Nut

32572

Washer

51743

Washer

51743

Washer

84460

Gasket

For service on the Sloan vessel,

phone 1-800-533-3450.

32572

Washer

51533

Nut

Kohler Co. 13 1044956-5-B

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